US7034244B2 - Method and apparatus of coordinating operational feedback in a plasma cutter - Google Patents
Method and apparatus of coordinating operational feedback in a plasma cutter Download PDFInfo
- Publication number
- US7034244B2 US7034244B2 US10/605,038 US60503803A US7034244B2 US 7034244 B2 US7034244 B2 US 7034244B2 US 60503803 A US60503803 A US 60503803A US 7034244 B2 US7034244 B2 US 7034244B2
- Authority
- US
- United States
- Prior art keywords
- plasma
- feedback
- power source
- indicator
- torch
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime, expires
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K10/00—Welding or cutting by means of a plasma
- B23K10/006—Control circuits therefor
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/26—Plasma torches
- H05H1/32—Plasma torches using an arc
- H05H1/34—Details, e.g. electrodes, nozzles
- H05H1/36—Circuit arrangements
Definitions
- Plasma cutting is a process in which an electric arc is used to cut a workpiece.
- Plasma cutters typically include a power source, an air supply, and a torch.
- the torch or plasma torch is used to create and maintain the arc and plasma that perform the cutting.
- the plasma cutting power source receives an input voltage from a transmission power line or generator and provides an output voltage to a pair of output terminals, one of which is connected to an electrode and the other of which is connected to the workpiece.
- the power source is supplied with operational feedback from the torch and a processor, disposed in the power source, interprets the data and controls the operation of the plasma cutter.
- the processor of the power source is provided with feedback about the position of the torch trigger and whether all necessary torch components are securely in place at the torch. From the feedback, the processor determines whether to initiate cutting, pause cutting, discontinue cutting, or augment the operation of the plasma cutter during cutting.
- This feedback is typically provided via dedicated communications lines. Therefore, for each form of feedback that is sent from the torch to the power source, an individual communications line is connected between the power supply and cutting torch.
- This parallel feedback system presents numerous drawbacks.
- plasma cutting is a high voltage process and therefore the user must be mindful that precautionary measures must be taken to avoid improper operation. As such, it is necessary to determine whether specific conditions are present prior to the initiation of cutting. For example, before the power source responds to a request for operational power at the torch, the processor of the power source typically determines whether a retaining cup, fastened at the torch tip and securing the electrode, is in place. This ensures that the torch is in operating condition prior to cutting.
- the number of feedbacks is limited by the parallel feedback system. Specifically, since the feedback must be sent from the torch to the power source, the feedback must travel over a control cord connecting the torch and power source.
- plasma cutters are regularly subjected to harsh operating conditions associated with the operating environment in which they are placed and the nature of plasma cutting.
- plasma cutters are commonly operated within large manufacturing environments or at an in-field site.
- the plasma torch it is not uncommon for the plasma torch to be regularly disconnected from the power source for cleaning and maintenance. This repeated disconnection and reconnection can be particularly damaging to the electrical connections of the parallel feedback system. In either case, if the parallel feedback system fails, the plasma cutter must be removed from service and repaired or otherwise serviced.
- a plasma cutting system including a plasma cutting power source, a plasma torch operationally connected to the plasma cutting power source, and a serialization circuit disposed within the plasma torch.
- the serialization circuit is configured to control transmission of multiple feedback signals from the plasma torch to the plasma cutting power source.
- a method for providing feedback from a plasma torch to a remote power source including receiving feedback from a plurality of sensors disposed in the plasma torch. The method also includes arranging the feedback in a queue and sending the feedback to a remote power source in an order the feedback is arranged in the queue.
- a plasma torch assembly including a torch body enclosing a plasma-cutting electrode and a plurality of sensors.
- the plurality of sensors is configured to provide feedback regarding at least operational conditions of a plasma torch.
- a serializer is disposed within the torch body to receive feedback from the plurality of sensors and configured to transmit the feedback to a remote processing unit via a single communications link.
- FIG. 1 is a perspective view of a plasma cutting system incorporating the present invention.
- FIG. 2 is a schematic representation of a feedback control system operable with the plasma cutting system shown in FIG. 1 .
- the present invention is directed to an operational feedback system of a plasma cutter.
- the serial communications feedback system allows the power source, where operational control is managed, to be supplied with diversified feedback regarding the plasma cutting process while reducing manufacturing costs and the potential for a communications breakdown due to operational wear.
- the plasma cutting system 10 is a high voltage system with maximum open circuit output voltages ranging from approximately 230 Volts Direct Current (VDC) to over 300 VDC.
- the plasma cutting system 10 includes a power source 12 to condition raw power and regulate/control the cutting process.
- the power source includes a processor that, as will be described, receives operational feedback and controls the plasma cutting system 10 accordingly.
- Power source 12 includes a lifting means, such as a handle 14 which effectuates transportation from one site to another.
- Connected to the power source 12 is a torch 16 via cord 18 .
- the torch 16 is defined at least by a torch body or housing 17 enclosing a plasma-cutting electrode 19 .
- the cord 18 provides the torch 16 with power and serves as a communications link between the torch 16 and power source 12 .
- the cord 18 contains two conductive paths. One conductive communications link or conductive path is dedicated to the transfer of power to energize the plasma-cutting electrode 19 and the other conductive path is dedicated to the transfer of feedback to the power source 12 .
- the cord 18 contains one conductive path between the torch 16 and power source 12 to transfer both operational feedback and power. Specifically, a single conductive path is contained within the cord 18 that simultaneously transfers power and feedback from the plasma torch regarding the plasma cutting process.
- a work clamp 20 which is designed to hold a workpiece (not shown) to be cut.
- a cable 22 designed to provide a return path for the cutting current from the torch through the workpiece and the work clamp 20 .
- Extending from a rear portion of power source 12 is power cable 24 having plug 26 for connecting the power source 12 to a portable power supply 28 or a transmission power receptacle (not shown).
- Power source 12 further includes an ON/OFF switch 30 .
- torch 16 is placed in close proximity to a workpiece connected to clamp 20 .
- a user may then activate a trigger lock (not shown), in response to which a feedback signal is sent from a trigger sensor disposed within the torch 16 and connected to the trigger lock in the torch 16 .
- the signal is received by a serializing circuit disposed within the torch 16 and placed in a queue.
- the trigger lock signal is sent to the power source 12 , via the cord 18 , where a processing unit, disposed in the power source 12 , processes the feedback.
- the user may then press the trigger switch (not shown).
- the trigger switch Upon pressing the trigger switch, another feedback signal is sent from the trigger sensor disposed within the torch 16 .
- the trigger switch feedback is again sent to the serializing circuit within trigger 16 where it is placed in a queue and, after passing through the queue, the signal is sent to the processing unit of the power source 12 .
- the power source processing unit causes power to be sent to the torch 16 to initiate a pilot arc. Shortly thereafter, a cutting arc is generated and the user may then slowly move the torch across the workpiece to cut the workpiece. The user may adjust the torch speed to reduce spark splatter and provide a more-penetrating cut.
- Additional sensors are included within the torch 16 to send additional feedback, specific to plasma cutting, back to the processing unit of power source 12 .
- sensors to monitor air pressure, tip and electrode type, safety trigger, and consumable life are included.
- Other additional sensors to provide feedback regarding a plurality of plasma cutting operations may also be included.
- sensors may be constructed and disposed within the torch 16 to send feedback regarding power source activation, cup position, shorted component, torch temperature, trigger position, operation amperage, current transfer, and voltage drop, as well as any other operational conditions capable of being monitored.
- the communications link also facilitates the transfer of power from the power source 12 to the torch 16 . Accordingly, the communications link serves dual purposes and a single conductive means is included within the cord 18 to transmit the feedback to the power source and the power to the torch 16 .
- a plurality of feedback sensors is disposed within plasma torch 16 including a consumable sensor 36 , an electrode sensor 38 , a cup sensor 40 , a trigger sensor 42 , an air pressure sensor 44 , a temperature sensor 46 , an amperage sensor 48 , and a voltage sensor 50 .
- this list of sensors is exemplary and is not exhaustive of those contemplated or applicable.
- Each sensor 35 – 50 is connected to transmit feedback sensory information through a serializing circuit 51 , which is also disposed within the plasma torch 16 .
- the serializing circuit 51 receives feedback from the sensors 38 – 50 across signal paths 52 – 66 and holds the feedback in a queue in the order that the feedback is received thereby allowing the feedback to pass in serial form to power source 12 for processing and/or application. It is contemplated that the serializing circuit may consist of analog components, digital components, or a combination thereof. As such, the feedback signals may be communicated as analog signals or discrete digital signals. After passing through the queue, the feedback is sent from the plasma torch 16 to the power source 12 where a processing unit 74 receives and interprets the feedback.
- an interrupt loop 68 for the serializing circuit includes an interrupt 70 .
- the interrupt 70 allows feedback that is vital to the operation of the plasma torch 16 , such as problematic operational feedback, to bypass the queue of the serializing circuit 51 and be sent directly to the power source 12 . As such, feedback that is vital to the operation of the plasma torch 16 is not delayed by the serialization circuit 51 .
- the interrupt 70 monitors the feedback across signal paths 52 – 66 for data associated with a potentially problematic operating condition and if feedback indicating the problematic condition is detected, the feedback is redirected to interrupt loop 68 to bypass the serializing circuit and transmitted to the processing unit of the power source 12 .
- a plasma cutting system includes a plasma cutting power source, a plasma torch operationally connect to the plasma cutting power source, and a serialization circuit disposed within the plasma torch to control transmission of multiple feedback signals from the plasma torch to the plasma cutting power source.
- a method for providing feedback from a plasma torch to a remote power source includes receiving feedback from a plurality of sensors disposed in the plasma torch. The method also includes arranging the feedback in a queue and sending the feedback to a remote power source in an order the feedback is arranged in the queue.
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- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Arc Welding In General (AREA)
- Plasma Technology (AREA)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/605,038 US7034244B2 (en) | 2003-09-03 | 2003-09-03 | Method and apparatus of coordinating operational feedback in a plasma cutter |
EP04016676A EP1513378A3 (de) | 2003-09-03 | 2004-07-15 | Verfahren und Vorrichtung zur Koordinierung von der Operationsrückkopplung in einem Plasmaschneidegerät |
CA002475316A CA2475316A1 (en) | 2003-09-03 | 2004-07-20 | Method and apparatus of coordinating operational feedback in a plasma cutter |
US11/164,050 US20060049152A1 (en) | 2003-09-03 | 2005-11-08 | Method and apparatus of coordinating operational feedback in a plasma cutter |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/605,038 US7034244B2 (en) | 2003-09-03 | 2003-09-03 | Method and apparatus of coordinating operational feedback in a plasma cutter |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/164,050 Continuation US20060049152A1 (en) | 2003-09-03 | 2005-11-08 | Method and apparatus of coordinating operational feedback in a plasma cutter |
Publications (2)
Publication Number | Publication Date |
---|---|
US20050045599A1 US20050045599A1 (en) | 2005-03-03 |
US7034244B2 true US7034244B2 (en) | 2006-04-25 |
Family
ID=34135446
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/605,038 Expired - Lifetime US7034244B2 (en) | 2003-09-03 | 2003-09-03 | Method and apparatus of coordinating operational feedback in a plasma cutter |
US11/164,050 Abandoned US20060049152A1 (en) | 2003-09-03 | 2005-11-08 | Method and apparatus of coordinating operational feedback in a plasma cutter |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/164,050 Abandoned US20060049152A1 (en) | 2003-09-03 | 2005-11-08 | Method and apparatus of coordinating operational feedback in a plasma cutter |
Country Status (3)
Country | Link |
---|---|
US (2) | US7034244B2 (de) |
EP (1) | EP1513378A3 (de) |
CA (1) | CA2475316A1 (de) |
Cited By (10)
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US20090212027A1 (en) * | 2008-02-21 | 2009-08-27 | Hypertherm, Inc. | Binary Signal Detection |
US10039178B2 (en) | 2010-07-16 | 2018-07-31 | Hypertherm, Inc. | Failure event detection in a plasma arc torch |
US10241091B2 (en) | 2015-06-04 | 2019-03-26 | Rolls-Royce Corporation | Diagnosis of thermal spray gun ignition |
US10274364B2 (en) | 2013-01-14 | 2019-04-30 | Virginia Tech Intellectual Properties, Inc. | Analysis of component having engineered internal space for fluid flow |
US10625359B2 (en) | 2018-04-06 | 2020-04-21 | The Esab Group Inc. | Automatic identification of components for welding and cutting torches |
US10695783B2 (en) | 2016-12-06 | 2020-06-30 | Rolls-Royce Corporation | System control based on acoustic signals |
US10724999B2 (en) | 2015-06-04 | 2020-07-28 | Rolls-Royce Corporation | Thermal spray diagnostics |
US11092983B2 (en) | 2018-06-18 | 2021-08-17 | Rolls-Royce Corporation | System control based on acoustic and image signals |
US11213910B2 (en) | 2019-09-19 | 2022-01-04 | The Esab Group Inc. | Torch indicator apparatus and methods |
US11267069B2 (en) | 2018-04-06 | 2022-03-08 | The Esab Group Inc. | Recognition of components for welding and cutting torches |
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US7375303B2 (en) * | 2004-11-16 | 2008-05-20 | Hypertherm, Inc. | Plasma arc torch having an electrode with internal passages |
US7807937B2 (en) * | 2005-01-03 | 2010-10-05 | Illinois Tool Works Inc. | Method and system of conserving plasma torch consumable |
US7709765B2 (en) * | 2005-12-28 | 2010-05-04 | Hypertherm, Inc. | Networking architecture for thermal processing system |
US7781699B2 (en) * | 2006-03-30 | 2010-08-24 | Illinois Tool Works Inc. | Plasma torch with post flow control |
US9931708B2 (en) * | 2006-07-27 | 2018-04-03 | Illinois Tool Works Inc. | Automatic consumable and torch length detection via pressure decay |
US8376336B2 (en) | 2008-06-18 | 2013-02-19 | Phd, Inc. | Strip off pin clamp |
US8963845B2 (en) | 2010-05-05 | 2015-02-24 | Google Technology Holdings LLC | Mobile device with temperature sensing capability and method of operating same |
US8751056B2 (en) | 2010-05-25 | 2014-06-10 | Motorola Mobility Llc | User computer device with temperature sensing capabilities and method of operating same |
US9103732B2 (en) | 2010-05-25 | 2015-08-11 | Google Technology Holdings LLC | User computer device with temperature sensing capabilities and method of operating same |
US10486260B2 (en) | 2012-04-04 | 2019-11-26 | Hypertherm, Inc. | Systems, methods, and devices for transmitting information to thermal processing systems |
US10455682B2 (en) | 2012-04-04 | 2019-10-22 | Hypertherm, Inc. | Optimization and control of material processing using a thermal processing torch |
US8963885B2 (en) | 2011-11-30 | 2015-02-24 | Google Technology Holdings LLC | Mobile device for interacting with an active stylus |
US9063591B2 (en) | 2011-11-30 | 2015-06-23 | Google Technology Holdings LLC | Active styluses for interacting with a mobile device |
US9737954B2 (en) | 2012-04-04 | 2017-08-22 | Hypertherm, Inc. | Automatically sensing consumable components in thermal processing systems |
US9672460B2 (en) | 2012-04-04 | 2017-06-06 | Hypertherm, Inc. | Configuring signal devices in thermal processing systems |
US20150332071A1 (en) | 2012-04-04 | 2015-11-19 | Hypertherm, Inc. | Configuring Signal Devices in Thermal Processing Systems |
US11783138B2 (en) | 2012-04-04 | 2023-10-10 | Hypertherm, Inc. | Configuring signal devices in thermal processing systems |
US9643273B2 (en) | 2013-10-14 | 2017-05-09 | Hypertherm, Inc. | Systems and methods for configuring a cutting or welding delivery device |
US9993934B2 (en) | 2014-03-07 | 2018-06-12 | Hyperthem, Inc. | Liquid pressurization pump and systems with data storage |
US10786924B2 (en) | 2014-03-07 | 2020-09-29 | Hypertherm, Inc. | Waterjet cutting head temperature sensor |
US20150269603A1 (en) | 2014-03-19 | 2015-09-24 | Hypertherm, Inc. | Methods for Developing Customer Loyalty Programs and Related Systems and Devices |
US10729454B2 (en) | 2014-09-10 | 2020-08-04 | Teleflex Life Sciences Limited | Guidewire capture |
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-
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- 2004-07-20 CA CA002475316A patent/CA2475316A1/en not_active Abandoned
-
2005
- 2005-11-08 US US11/164,050 patent/US20060049152A1/en not_active Abandoned
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Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090212027A1 (en) * | 2008-02-21 | 2009-08-27 | Hypertherm, Inc. | Binary Signal Detection |
US10039178B2 (en) | 2010-07-16 | 2018-07-31 | Hypertherm, Inc. | Failure event detection in a plasma arc torch |
US10274364B2 (en) | 2013-01-14 | 2019-04-30 | Virginia Tech Intellectual Properties, Inc. | Analysis of component having engineered internal space for fluid flow |
US10241091B2 (en) | 2015-06-04 | 2019-03-26 | Rolls-Royce Corporation | Diagnosis of thermal spray gun ignition |
US10724999B2 (en) | 2015-06-04 | 2020-07-28 | Rolls-Royce Corporation | Thermal spray diagnostics |
US10695783B2 (en) | 2016-12-06 | 2020-06-30 | Rolls-Royce Corporation | System control based on acoustic signals |
US10625359B2 (en) | 2018-04-06 | 2020-04-21 | The Esab Group Inc. | Automatic identification of components for welding and cutting torches |
US11267069B2 (en) | 2018-04-06 | 2022-03-08 | The Esab Group Inc. | Recognition of components for welding and cutting torches |
US11883896B2 (en) | 2018-04-06 | 2024-01-30 | The Esab Group, Inc. | Recognition of components for welding and cutting torches |
US11092983B2 (en) | 2018-06-18 | 2021-08-17 | Rolls-Royce Corporation | System control based on acoustic and image signals |
US11213910B2 (en) | 2019-09-19 | 2022-01-04 | The Esab Group Inc. | Torch indicator apparatus and methods |
Also Published As
Publication number | Publication date |
---|---|
CA2475316A1 (en) | 2005-03-03 |
EP1513378A2 (de) | 2005-03-09 |
EP1513378A3 (de) | 2007-07-04 |
US20050045599A1 (en) | 2005-03-03 |
US20060049152A1 (en) | 2006-03-09 |
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